JP6765077B2 - Solar cell module and manufacturing method of solar cell module - Google Patents

Description

The present disclosure relates to a solar cell module and a method for manufacturing the same.

In the solar cell module, a string formed by connecting a plurality of solar cell cells with a first wiring material is provided on a first protective member provided on the light receiving surface side of the solar cell and a second protective member provided on the back surface side of the solar cell. It has a structure laminated by using a protective member and a sealing material. The solar cell module is further provided with a second wiring material that is connected to the first wiring material at a position that does not overlap the solar cell. In the solar cell module disclosed in Patent Document 1, in order to conceal the second wiring material and improve the design of the module, the surface of the second wiring material facing the first protective member side is made of a colored resin. It is covered with a layer.

Japanese Unexamined Patent Publication No. 2001-339089

By the way, a part of the first wiring material connected to the second wiring material is formed between the solar cell and the second wiring material and bent toward the second protective member side. In the solar cell module of Patent Document 1, the end portion of the resin layer having a certain thickness overlaps with the bent portion of the first wiring material in the thickness direction of the module. Therefore, particularly in the laminating step, a large load is applied to the bent portion of the first wiring material due to the end portion of the resin layer, and the end portion of the solar cell to which the wiring material is attached is easily cracked.

The solar cell module according to one aspect of the present disclosure is provided on a plurality of solar cells, a first protective member provided on the light receiving surface side of the plurality of solar cells, and on the back surface side of the plurality of solar cells. The second protective member, the first wiring material that connects the adjacent solar cells, the second wiring material that is connected to the first wiring material at a position that does not overlap with the solar cells, and the first. The sealing material filled between the 1 protective member and the 2nd protective member is provided between the 1st protective member and the 2nd wiring material so as not to overlap with the solar cell, and the first (2) A concealing sheet for hiding the wiring material is provided, and the sealing material is filled between the concealing sheet and the second wiring material, and at least one solar cell and the first protective member. Among the solar cells, at least one solar cell includes an end portion of the thick film portion and a thick film portion thicker than between the other solar cell and the first protective member. It is warped toward the second protective member at a position where it overlaps in the thickness direction.

The method for manufacturing a solar cell module according to one aspect of the present disclosure includes a plurality of solar cells, a first protective member provided on the light receiving surface side of the plurality of solar cells, and the back surface of the plurality of solar cells. A second protective member provided on the side, a first wiring material for connecting the adjacent solar cells, and a second wiring material connected to the first wiring material at a position not overlapping with the solar cells. A method for manufacturing a solar cell module comprising the above, wherein a first sealing material is arranged between the first protective member and the plurality of solar cells, and the second protective member and the plurality of solar cells are provided. A step of arranging a second sealing material between the cell and a step of arranging a third sealing material and a concealing sheet in an overlapping manner between the first sealing material and the second wiring material, and the above-mentioned The first protective member and the third protective member are provided with a laminating step of pressing each of the protective members in a direction approaching each other while heating each encapsulant so that the concealing sheet does not overlap with the solar cell. The third encapsulant is arranged between the encapsulant and the third encapsulant so as to protrude from between the concealing sheet and the second wiring material and to be located on a light receiving surface of at least one solar cell. Will be done.

According to one aspect of the present disclosure, the second wiring material can be concealed while suppressing the cracking of the solar cell by preventing a large load from acting on the bent portion of the first wiring material, and the design is excellent. We can provide solar cell modules.

It is a top view which shows a part of the solar cell module which is an example of embodiment. It is a figure which shows a part of the cross section of AA line in FIG. It is a figure for demonstrating the manufacturing method of the solar cell module which is an example of embodiment. It is a figure for demonstrating the manufacturing method of the solar cell module which is another example of embodiment. It is a figure for demonstrating the manufacturing method of the solar cell module which is a comparative example.

Hereinafter, an example of the embodiment will be described in detail with reference to the drawings. The drawings referred to in the embodiments are schematically described, and the dimensional ratios and the like of the components drawn in the drawings may differ from the actual ones. Specific dimensional ratios should be determined in consideration of the following explanation. In addition, it is assumed from the beginning that each component of a plurality of embodiments described below is selectively combined.

In the present specification, the description of "abbreviated to" is intended to include not only completely the same but also substantially the same when "substantially the same" is taken as an example. Further, the description such as "providing the second member on the first member" is not intended only when the first and second members are provided in direct contact with each other, unless otherwise specified. This description includes the case where another member is present between the first and second members.

FIG. 1 is a plan view showing a part of the solar cell module 10 which is an example of the embodiment, and FIG. 2 is a view showing a part of the AA line cross section in FIG. As illustrated in FIGS. 1 and 2, the solar cell module 10 includes a plurality of solar cells 11, a first protective member 12 provided on the light receiving surface side of the plurality of solar cells 11, and a plurality of solar cells. A second protective member 13 provided on the back surface side of the cell 11 is provided. Further, the solar cell module 10 includes a first wiring material 15 that connects adjacent solar cell 11s, and a second wiring material 16 that is connected to the first wiring material 15 at a position that does not overlap with the solar cell 11. A sealing material 14 filled between the first protective member 12 and the second protective member 13 is provided.

The solar cell module 10 is further provided between the first protective member 12 and the second protective member 13 so as not to overlap the solar cell 11, and includes a concealing sheet 20 that hides the second wiring material 16. As will be described in detail later, the sealing material 14 is filled between the concealing sheet 20 and the second wiring material 16, and is placed between at least one solar cell 11 and the first protective member 12. Includes a thick film portion 24 that is thicker than between the solar cell 11 and the first protective member 12. The at least one solar cell 11 is warped toward the second protective member 13 at a position where it overlaps the end P of the thick film portion 24 of the sealing material 14 in the thickness direction of the module.

Here, the "light receiving surface" of the solar cell 11 means a surface on which light is mainly incident, and the "back surface" means a surface opposite to the light receiving surface. Of the light incident on the solar cell 11, 50% or more (for example, approximately 100%) is incident from the light receiving surface side. The terms of the light receiving surface and the back surface are also used for the photoelectric conversion unit and the like.

Each of the plurality of solar cell cells 11 has a photoelectric conversion unit that generates carriers by receiving sunlight, and a collector electrode that is provided on the photoelectric conversion unit and collects carriers. The photoelectric conversion unit has, for example, a substantially square shape in a plan view in which four corners are cut diagonally. The photoelectric conversion unit generally exhibits black or dark blue. In the present embodiment, a light receiving surface electrode formed on the light receiving surface of the photoelectric conversion unit and a back surface electrode formed on the back surface are provided as the collecting electrode.

The photoelectric conversion unit includes, for example, a semiconductor substrate such as crystalline silicon (Si), gallium arsenide (GaAs), or indium phosphide (InP), an amorphous semiconductor layer formed on the semiconductor substrate, and an amorphous semiconductor layer. It has a transparent conductive layer formed in. As a specific example, an i-type amorphous silicon layer, a p-type amorphous silicon layer, and a transparent conductive layer are sequentially formed on one surface of an n-type single crystal silicon substrate, and an i-type amorphous silicon layer is formed on the other surface. Examples thereof include a structure in which a silicon layer, an n-type amorphous silicon layer, and a transparent conductive layer are formed in this order. The transparent conductive layer is composed of a transparent conductive oxide obtained by doping a metal oxide such as indium oxide or zinc oxide with tin (Sn), antimony (Sb) or the like.

The collector electrode preferably includes a plurality of finger electrodes. However, the back surface electrode may be an electrode that covers substantially the entire back surface of the photoelectric conversion unit. The plurality of finger electrodes are fine line-shaped electrodes formed substantially parallel to each other. The collector electrode may include a busbar electrode that is wider than the finger electrode and is substantially orthogonal to each finger electrode. When the bus bar electrode is provided, the first wiring material 15 is attached along the bus bar electrode. Since the collector electrode is a fine wire-shaped electrode, the color of the solar cell 11 largely depends on the color of the photoelectric conversion unit. Therefore, the solar cell 11 exhibits a black color or a dark blue color.

The solar cell module 10 is composed of a solar cell panel 30 and a metal frame 31 attached to the peripheral edge of the solar cell panel 30 and protecting the peripheral edge. The solar cell panel 30 has, for example, a substantially rectangular shape in a plan view, but the shape of the panel can be changed as appropriate, and may be a pentagonal panel, a panel having a curved surface, or the like. A terminal box (not shown) containing a bypass diode may be provided on the back side of the solar cell panel 30.

In the solar cell module 10, a plurality of solar cell cells 11 are arranged on substantially the same plane. Adjacent solar cell 11s are connected in series by a first wiring material 15, whereby the string 18 of the solar cell 11 is formed. The first wiring material 15 bends between adjacent solar cell 11s in the thickness direction of the module, and an adhesive or the like is used on the light receiving surface of one solar cell 11 and the back surface of the other solar cell 11, respectively. It is attached and electrically connected to the collector electrode of the solar cell 11. The first wiring material 15 is generally called an interconnector or a tab.

The solar cell module 10 has a plurality of strings 18 in which a plurality of solar cell cells 11 are arranged in a row. The plurality of strings 18 are composed of, for example, the same number of solar cells 11, and are arranged substantially parallel to each other. A plurality of second wiring members 16 are provided on both sides of each string 18 in the longitudinal direction so as to be substantially orthogonal to the longitudinal direction at positions not overlapping with the solar cell 11. The second wiring material 16 is generally called a crossover tab. In FIG. 1, one side of each string 18 in the longitudinal direction is shown, but a plurality of second wiring members 16 are also provided on the other side.

The first wiring material 15 and the second wiring material 16 are both flat wire members and generally have a silver color. Each wiring material may have, for example, a conductive core material and a plating layer formed on the surface of the core material. The core material is mainly composed of a metal such as copper (Cu) or aluminum (Al). An example of the plating layer is a layer containing silver (Ag), nickel (Ni), a low melting point alloy used as solder, or the like as a main component. The second wiring material 16 has a wider width than the first wiring material 15 and is more conspicuous. Therefore, in the solar cell module 10, a concealing sheet 20 that covers the second wiring material 16 is provided to hide the second wiring material 16.

The second wiring material 16 connects the two strings 18 in series. Further, a part of the second wiring material 16 is connected to the terminal box via the output wiring material 17. That is, the second wiring material 16 includes a wiring material that connects the strings 18 to each other and a wiring material that connects one string 18 and the terminal box. The output wiring material 17 is also connected to a part of the second wiring material 16 that connects the strings 18. By connecting the terminal box containing the bypass diode and the second wiring material 16 in this way, for example, when a part of the solar cell 11 is in the shadow, the string 18 including the cell is bypassed. ..

In the example shown in FIG. 1, two second wiring members 16A connecting the strings 18 are arranged on one side in the longitudinal direction of the six strings 18 on substantially the same straight line. The two second wiring members 16A connect two adjacent strings 18 to each other for four located in the center of the six strings 18. Each second wiring material 16A is slightly shorter than the length in the lateral direction for two rows of the string 18, and is arranged close to the solar cell 11. The distance between the second wiring material 16A and the solar cell 11 is, for example, about 1 mm to 3 mm.

On one side of the six strings 18 in the longitudinal direction, two second wiring members 16B connecting the one string 18 and the terminal box are further arranged on substantially the same straight line. The two second wiring materials 16B connect the strings 18 located at both ends of the six strings 18 to the terminal box, respectively. Each of the second wiring materials 16B is slightly shorter than the length of the three rows of the strings 18 in the lateral direction, and is arranged substantially parallel to the two second wiring materials 16A connecting the strings 18. In the example shown in FIG. 1, the second wiring material 16A and the second wiring material 16B are arranged in this order from the solar cell 11 side.

The first wiring material 15 extending from the solar cell 11 located at both ends of each string 18 is connected to the second wiring material 16. In the following, for convenience of explanation, the solar cell 11 located at both ends in the longitudinal direction of each string 18 may be referred to as a “solar cell 11A”, and the other solar cell 11 may be referred to as a “solar cell 11B”. The first wiring material 15 includes a wiring material for connecting the solar cells 11 to each other and a wiring material for connecting one solar cell 11 and the second wiring material 16.

As illustrated in FIG. 2, a part of the first wiring material 15 connected to the second wiring material 16 is formed (bent) between the solar cell 11 and the second wiring material 16. 2 It has a bent portion 15a that is bent on the protective member 13 side. In the present embodiment, of the first wiring material 15 connected to the second wiring material 16, the bent portion 15a is formed on the first wiring material 15 attached to the light receiving surface of the solar cell 11A. The first wiring material 15 is bent toward the second protective member 13 side between the end of the solar cell 11A and the second wiring material 16, and faces the second protective member 13 side of the second wiring material 16. It is joined to the surface. The bent portion 15a is also formed on the first wiring material 15 that connects the solar cells 11 to each other.

As described above, in the solar cell module 10, a string 18 formed by connecting a plurality of solar cell cells 11 with a first wiring material 15 is a first protective member 12, a second protective member 13, a sealing material 14, and the like. Has a structure laminated using. In the present embodiment, the sealing material 14 is filled between the solar cell 11 and the first protective member 12 between the first sealing material 14A and between the solar cell 11 and the second protective member 13. It shall include the filled second sealing material 14B. Further, the sealing material 14 includes a third sealing material 14C filled between the concealing sheet 20 and the second wiring material 16. As will be described in detail later, a part of the third sealing material 14C forms the thick film portion 24, and the end portion P of the third sealing material 14C is located on the light receiving surface of at least one solar cell 11. ing.

As the first protective member 12, for example, a transparent member such as a glass substrate, a resin substrate, or a resin film can be used. Considering heat resistance, durability, etc., it is preferable to use a glass substrate. The thickness of the glass substrate is, for example, about 0.5 mm to 6 mm. In the present embodiment, a colorless and transparent glass substrate is used as the first protective member 12.

As the second protective member 13, the same transparent member as the first protective member 12 may be used, or an opaque member may be used. In this embodiment, a resin film is used as the second protective member 13. The resin film is not particularly limited, but a preferable example is a polyethylene terephthalate (PET) film. The thickness of the second protective member 13 is, for example, about 50 to 300 μm, preferably 100 μm to 200 μm.

The second protective member 13 is preferably of the same color as the solar cell 11. Since the solar cell 11 is black or dark blue, for example, the color of the second protective member 13 is black or dark blue. If the solar cell 11 and the second protective member 13 have the same color, the solar cell module 10 can be seen from the gap of each solar cell 11 when viewed from the light receiving surface side (first protective member 12 side). 2 The protective member 13 becomes inconspicuous, and the design of the module is improved.

The second protective member 13 preferably has an absorption rate of visible light having a wavelength of 380 nm to 780 nm of 30% or more. Hereinafter, unless otherwise specified, light having a wavelength of 380 nm to 780 nm is referred to as visible light. The second protective member 13 may have an absorption rate of 30% or more for a part of visible light, but more preferably for all visible light, that is, for all wavelengths of 380 nm to 780 nm. is there. In this case, the color of the second protective member 13 tends to be black, dark blue, or a color close to the same as the color of the solar cell 11. When the second protective member 13 is made black, the visible light absorption rate of the second protective member 13 is preferably 50% or more, more preferably 60% or more, particularly preferably 70% or more, and most preferably 80% or more. is there.

A similar resin film can be applied to the second protective member 13 and the concealing sheet 20. That is, the concealing sheet 20 preferably has an absorption rate of visible light of 30% or more, and more preferably an absorption rate of 30% or more for all visible light. The visible light absorption rate of the concealing sheet 20 is, for example, 80% or more. It is preferable that the second protective member 13 and the concealing sheet 20 have substantially the same visible light absorption rate. In this case, the concealing sheet 20 becomes inconspicuous, and for example, the colors of the solar cell 11, the second protective member 13, and the concealing sheet 20 are unified to further improve the design of the module. It is preferable that these colors have the same hue as well as hue.

The light absorption rate A (%) of the second protective member 13 and the concealment sheet 20 is the light transmittance T (%) and the light reflectance R of each layer using a spectrophotometer capable of measuring the target wavelength range. (%) Can be measured and calculated by the following formula.
A = 100-TR
The measurement of light transmittance and light reflectance can be performed based on JIS-K7375. As the spectrophotometer, SolidSpec-3700 manufactured by Shimadzu Corporation can be used.

As described above, the concealing sheet 20 is provided between the first protective member 12 and the second wiring material 16. The concealing sheet 20 plays a role of concealing the second wiring material 16, and is colored so that the second wiring material 16 cannot be seen from the first protective member 12 side. Therefore, it is necessary to arrange the concealing sheet 20 at a position that does not overlap with the solar cell 11 so as not to affect the power generation of the solar cell 11. Further, for example, the concealing sheet 20 is arranged closer to the second protective member 13 than each solar cell 11, and the surface of the concealing sheet 20 facing the first protective member 12 is closer to the light receiving surface of each solar cell 11. It is located on the 12th side of the first protective member.

The concealing sheet 20 is preferably of the same color as the second protective member 13, for example, may be white, but more preferably the concealing sheet 20 and the second protective member 13 are of the same color as the solar cell 11. .. A suitable concealing sheet 20 has a lower visible light reflectance than the second wiring material 16 and exhibits black or dark blue. The thickness of the concealing sheet 20 is, for example, about 50 to 300 μm, preferably 100 μm to 200 μm, like the second protective member 13.

In the present embodiment, two concealing sheets 20 are provided to cover each of the second wiring members 16 arranged on both sides in the longitudinal direction of each string 18. One concealing sheet 20 may be provided for each of the second wiring materials 16 so as to cover the four second wiring materials 16 arranged on one side in the longitudinal direction of each string 18, for example. However, in consideration of productivity and the like, it is preferable to conceal the four second wiring materials 16 by using one concealing sheet 20. In the example shown in FIG. 1, a strip-shaped concealing sheet 20 that extends long in the longitudinal direction of the second wiring material 16 and has a substantially constant width is provided. The width of the concealing sheet 20 is, for example, about 2 cm to 4 cm.

The concealing sheet 20 is larger than the range in which each of the second wiring materials 16 is arranged so that all the second wiring materials 16 can be concealed even if the positions are slightly displaced, and the widths of the second wiring materials 16A and 16B and them are large. It is formed wider than the length obtained by adding the intervals of. Therefore, one end of the concealing sheet 20 in the width direction overlaps the bent portion 15a of the first wiring material 15 in the thickness direction of the module. In this case, a large load (pressure) is likely to act on the bent portion 15a in the laminating step, but the pressure can be dispersed by the third sealing material 14C in the solar cell module 10.

The concealing sheet 20 (the same applies to the second protective member 13) has a structure in which a coloring material that absorbs visible light is dispersed in the resin constituting the resin film. Alternatively, the concealing sheet 20 may have a structure in which a plurality of resin layers are laminated, and at least one layer of each resin layer may contain a coloring material. Further, it may be a resin film having a colored layer printed on its surface. The resin film is preferably composed of a resin that has higher heat resistance than the sealing material 14 (for example, a softening point, a glass transition point, or a melting point) and does not melt in the laminating step.

When the concealing sheet 20 is black or dark blue, a black pigment such as carbon black, aniline black, titanium black, non-magnetic ferrite, or magnetite can be used as the coloring material. Alternatively, the color of the concealing sheet 20 may be adjusted to black or dark blue by mixing a yellow pigment, a red pigment, a blue pigment, and the like. The content of the coloring material is, for example, about 5% by volume to 50% by volume with respect to the volume of the concealing sheet 20.

In order to make the concealing sheet 20 black or dark blue and to increase the transmittance of near-infrared light having a wavelength of 780 nm to 1200 nm, a coloring material such as perylene black, bismuth sulfide, lumogen black, or silver-tin alloy particles is used. May be good. In this case, the near-infrared light transmitted through the concealing sheet 20 is reflected by, for example, the second wiring material 16 and enters the solar cell 11, and the light utilization efficiency is improved.

Since the concealing sheet 20 does not melt in, for example, the laminating process, the sealing material 14 is also placed between the concealing sheet 20 and the second wiring material 16 in order to ensure the adhesiveness between the concealing sheet 20 and the second wiring material 16. Is filled. Further, the sealing material 14 filled between the concealing sheet 20 and the second wiring material 16 reduces the load on the bent portion 15a of the first wiring material 15 by the concealing sheet 20. In the present embodiment, the third encapsulant 14C is described as being filled, but the same encapsulant may be applied to each encapsulant, and in that case, the interface of each encapsulant is formed after the laminating step. Not clearly formed.

Examples of the resin constituting the sealing material 14 include polyolefins, polyesters, epoxy resins, copolymers of α-olefins and vinyl carboxylate, and the like. Of these, polyolefins and copolymers of α-olefins and vinyl carboxylate (ethylene-vinyl acetate copolymer: EVA) are preferable. For example, polyolefin may be applied to the first encapsulant 14A, and EVA may be applied to the second encapsulant 14B and the third encapsulant 14C. Further, polyolefin may be used for the first sealing material 14A and the second sealing material 14B, and EVA may be used for the third sealing material 14C. The second sealing material 14B may contain a coloring material, but in the present embodiment, it is assumed that the second sealing material 14B is made of a colorless and transparent resin.

The thicknesses of the first encapsulant 14A, the second encapsulant 14B, and the third encapsulant 14C are, for example, 300 μm to 800 μm, and the thicknesses of each may be substantially the same or different from each other. .. The third sealing material 14C may be thinner than the first sealing material 14A and the second sealing material 14B.

As described above, the sealing material 14 is thicker between at least one solar cell 11 and the first protective member 12 than between the other solar cell 11 and the first protective member 12. The thick film portion 24 is included. In the present embodiment, a part of the third sealing material 14C forms the thick film portion 24, and the end portion P of the third sealing material 14C is located on the light receiving surface of at least one solar cell 11. That is, the third sealing material 14C protrudes from under the concealing sheet 20, and the end portion P of the third sealing material 14C (thick film portion 24) is in the direction of the bending portion 15a of the first wiring material 15 and the thickness of the module. It exists not at the overlapping position but at the position where it overlaps with the solar cell 11.

Like the concealing sheet 20, the third sealing material 14C is formed in a strip shape having a substantially constant width and extending in the longitudinal direction of the second wiring material 16. The width of the third sealing material 14C is wider than the width of the concealing sheet 20, and a part of the third sealing material 14C (thick film portion 24) receives light from the six solar cells 11A located at the ends of each string 18. It is placed on the surface. The width of the third sealing material 14C is, for example, about 3 cm to 7 cm. In FIG. 1, dot hatching is attached to the third sealing material 14C (thick film portion 24) existing on the light receiving surface of the solar cell 11A (actually transparent).

The third sealing material 14C is provided so as to intervene in the entire area between, for example, the concealing sheet 20 and the second wiring material 16 and cover 10% to 40% of the light receiving surface of the six solar cell 11A. The size of the third sealing material 14C of the portion extending on the light receiving surface of the solar cell 11A, that is, the width of the thick film portion 24 is, for example, 1 cm to 3 cm. The third sealing material 14C may be arranged so that the end portion P and the bent portion 15a do not overlap in the thickness direction of the module, and may be arranged so as to cover, for example, the solar cells 11A and 11B. .. However, from the viewpoint of material cost reduction and the like, it is preferable to provide the third sealing material 14C so that the end portion P is located on the light receiving surface of the solar cell 11A closest to the second wiring material 16. ..

In the present embodiment, the end P is located on the light receiving surface of the solar cell 11A closest to the second wiring material 16, and the solar cell 11A is warped toward the second protective member 13. In the solar cell 11A, the portion covered with the third sealing material 14C is pressed from the first protective member 12 side in the laminating process, and the second protective member starts from the position 11p where the end portion P and the module overlap in the thickness direction. It curves to the 13 side. That is, by extending the third sealing material 14C onto the light receiving surface of the solar cell 11A, a part of the pressure generated due to the thickness of the concealing sheet 20 and the third sealing material 14C is generated by the solar cell 11A. It receives and prevents the pressure from concentrating on the bent portion 15a. This prevents the end of the solar cell 11 from cracking.

In the solar cell 11A, the portion where the third sealing material 14C (thick film portion 24) exists on the light receiving surface, for example, the range of 1 cm to 3 cm from the end on the second wiring material 16 side is the second protective member 13 side. It is warped. The solar cell 11A is gently curved, for example, from the position 11p corresponding to the end portion P toward the end portion on the side of the second wiring material 16 so as to gradually approach the second protective member 13. Although it depends on the thickness of the third sealing material 14C, for example, the length from the light receiving surface of the flat portion of the solar cell 11A to the light receiving surface of the end portion on the second protective member 13 side along the thickness direction of the module. The solar cell 11A is curved so that the value is 300 μm to 800 μm. The six solar cells 11A may be similarly curved.

Further, the second protective member 13 may bulge to the back side at the portion where the concealing sheet 20 and the third sealing material 14C are provided. Similar to the solar cell 11A, the second protective member 13 bulges toward the back surface side from, for example, a position where the end portion P and the module overlap in the thickness direction, or a vicinity thereof.

Hereinafter, an example of a method for manufacturing the solar cell module 10 having the above configuration will be described with reference to FIG. FIG. 3 shows a state before laminating in which each component of the solar cell module 10 is separated. Further, FIG. 4 shows another example of the embodiment. Here, FIG. 5 is referred to as a comparative example.

The manufacturing process of the solar cell module 10 having the above configuration includes the following steps.
(1) A step of arranging the first sealing material 14A between the first protective member 12 and the plurality of solar cells 11.
(2) A step of arranging the second sealing material 14B between the second protective member 13 and the plurality of solar cells 11.
(3) A step of superimposing the third sealing material 14C and the concealing sheet 20 between the first protective member 12 and the second wiring material 16.
(4) A laminating step of pressing the first protective member 12 and the second protective member 13 in a direction approaching each other while heating each of the sealing materials.

By the steps (1) to (3) above, the constituent members are laminated in the order shown in FIG. In the present embodiment, a resin film having the same size is used for the second protective member 13, the first sealing material 14A, and the second sealing material 14B. A strip-shaped resin film having a substantially constant width is used for the concealing sheet 20, and a resin film wider than the concealing sheet 20 is used for the third sealing material 14C. The first protective member 13 and the concealing sheet 20 exhibit, for example, black or dark blue.

In the laminating step of the above (4), the laminated body obtained in the above steps (1) to (3) is heated to about 150 ° C. in a vacuum state, for example. After that, the solar cell panel 30 is manufactured by continuing heating for a predetermined time while pressing the laminated body under atmospheric pressure. At this time, the string 18 is pressed from both sides of the first protective member 12 and the second protective member 13, and pressure acts on the string 18. Finally, the frame 31 and the like are attached to the solar cell panel 30 to obtain the solar cell module 10.

As illustrated in FIG. 3, in the manufacturing process of the solar cell module 10, the concealing sheet 20 is arranged between the first protective member 12 and the third sealing material 14C so as not to overlap with the solar cell 11. Then, a part of the third sealing material 14C protrudes from between the concealing sheet 20 and the second wiring material 16 and is located on the light receiving surface of at least one solar cell 11. Place 14C. In the example shown in FIG. 3, the third sealing material 14C is arranged so that the end portion P is located on the light receiving surface of the solar cell 11A closest to the second wiring material 16.

In the example shown in FIG. 4, the third sealing material 14D is arranged so that a part of the third sealing material 14D is located on the light receiving surface of the solar cell 11A. Common. On the other hand, the third sealing material 14D is larger than the third sealing material 14C, and is also arranged on the light receiving surface of the solar cell 11B, for example. As the third sealing material 14D, a resin film having substantially the same size as the first sealing material 14A may be used. In this case, the third encapsulant 14D covers all the solar cells 11, and the end of the encapsulant is not located on the light receiving surface of the solar cell 11, but is located near the end of the solar panel 30. To do.

In the examples shown in FIGS. 3 and 4, the ends of the third sealing materials 14C and 14D do not exist at positions overlapping the bent portions 15a of the first wiring material 15 in the thickness direction of the laminate, whereas FIG. 5 In the comparative example shown in (1), the end portion 101 of the third sealing material 100 exists at a position where it overlaps with the bent portion 15a. When the laminates shown in FIGS. 3 to 5 are provided for the laminating process and compressed, in the comparative example, the bent portion 15a is pressed by the end portion of the concealing sheet 20 and the end portion 101 of the third sealing material 100 to be bent. A large pressure acts on the portion 15a. When a large pressure acts on the bent portion 15a of the first wiring material 15, a problem may occur in which the end portion of the solar cell 11A to which the first wiring material 15 is attached is cracked.

On the other hand, when the laminates shown in FIGS. 3 and 4 are used, the pressure acting on the bent portion 15a is dispersed by the third sealing materials 14C and 14D extending toward the solar cell 11A, and the pressure is concerned. Is greatly reduced. When the laminated body shown in FIG. 3 is used, the solar cell 11A in which the end portion P of the third sealing material 14C is located on the light receiving surface is gently curved toward the second protective member 13 side in the laminating step. To do. That is, the solar cell 11A receives a part of the pressure generated due to the thickness of the concealing sheet 20 and the third sealing material 14C, so that the cell cracking due to the concentration on the bent portion 15a can be prevented.

When the third sealing material 14D covers all the solar cell 11 and the second wiring material 16, for example, the cell cracking can be prevented without bending each solar cell 11. When the end portion of the third sealing material 14D is located on the light receiving surface of the solar cell 11B, the solar cell 11B is gently curved toward the second protective member 13 side in the laminating step. Considering the material cost, it is preferable to use the third sealing material 14C rather than the third sealing material 14D.

The colors of the concealing sheet 20 and the second protective member 13 are not limited to black and navy blue, and are completely different colors from the solar cell 11 (for example, yellow, green, red, depending on the design required in the market, for example. It is also possible to make it white (white, etc.). As described above, the color of the concealing sheet 20 is substantially black if the visible light absorption rate is 50% or more in a wide range of wavelengths of 380 nm to 780 nm, but the light absorption rate is high only at a specific wavelength and a part of visible light. The color of the concealing sheet 20 is yellow, green, red, or the like. When the color of the concealing sheet 20 is red, a red pigment may be used.

10 Solar cell module, 11, 11A, 11B Solar cell, 12 1st protective member, 13 2nd protective member, 14 encapsulant, 14A 1st encapsulant, 14B 2nd encapsulant, 14C 3rd encapsulant Material, 15 1st wiring material, 15a bent part, 16, 16A, 16B 2nd wiring material, 17 output wiring material, 18 strings, 20 concealment sheet, 24 thick film part, 30 solar cell panel, 31 frame, P end Department

Claims (7)

With multiple solar cells
A first protective member provided on the light receiving surface side of the plurality of solar cells, and
A second protective member provided on the back surface side of the plurality of solar cells, and
The first wiring material that connects the adjacent solar cells to each other,
A second wiring material connected to the first wiring material at a position not overlapping the solar cell,
A sealing material filled between the first protective member and the second protective member,
A concealing sheet provided between the first protective member and the second wiring material so as not to overlap with the solar cell and hide the second wiring material.
With
The sealing material is filled between the concealing sheet and the second wiring material, and between at least one solar cell and the first protective member, the other solar cell and the other solar cell and the above. Includes a thick film portion that is thicker than between the first protective member
A solar cell module in which at least one solar cell is warped toward the second protective member at a position where the end of the thick film portion and the end of the thick film portion overlap in the thickness direction of the module. The first aspect of claim 1, wherein the end of the thick film portion is located on the light receiving surface of the solar cell closest to the second wiring material, and the solar cell is warped toward the second protective member. Solar cell module. The solar cell module according to claim 1 or 2, wherein the second protective member and the concealing sheet have an absorption rate of visible light having a wavelength of 380 nm to 780 nm of 30% or more. The solar cell module according to claim 3, wherein the second protective member and the concealing sheet have substantially the same absorption rate of visible light. The sealing material is filled between the first sealing material filled between the first protective member and the plurality of solar cells, and between the second protective member and the plurality of solar cells. The second sealing material and the third sealing material filled between the concealing sheet and the second wiring material are included.
Claims 1 to 4 in which a part of the third sealing material forms the thick film portion, and the end portion of the third sealing material is located on a light receiving surface of at least one solar cell. The solar cell module according to any one of the above. A plurality of solar cells, a first protective member provided on the light receiving surface side of the plurality of solar cells, a second protective member provided on the back surface side of the plurality of solar cells, and the sun adjacent to each other. A method for manufacturing a solar cell module, comprising: a first wiring material for connecting battery cells to each other and a second wiring material to be connected to the first wiring material at a position not overlapping with the solar cell.
A step of arranging the first sealing material between the first protective member and the plurality of solar cells, and
A step of arranging a second sealing material between the second protective member and the plurality of solar cells, and
A step of superimposing the third sealing material and the concealing sheet between the first sealing material and the second wiring material, and
A laminating step of pressing each of the protective members in a direction approaching each other while heating each of the sealing materials.
With
The concealing sheet is arranged between the first protective member and the third sealing material so as not to overlap with the solar cell.
A method for manufacturing a solar cell module, wherein the third sealing material protrudes from between the concealing sheet and the second wiring material and is arranged so as to be located on a light receiving surface of at least one solar cell. The solar cell according to claim 6, wherein the third encapsulant is arranged so that an end portion of the encapsulant is located on a light receiving surface of the solar cell closest to the second wiring material. How to make the module.

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